Hybrid heater

ABSTRACT

A water heater includes a heat exchanger, a heat pump, a first valve in fluid communication with the heat exchanger and the heat pump, and a controller configured to control the first valve. The first valve can be configured to direct water flow toward at least one of the gas heater or the electric heat pump. A second valve in fluid communication with the first valve and the heat pump can be provided, and the controller can be further configured to control the second valve. A water heater inlet and a water heater outlet can be included and in fluid communication with the first valve, and the controller can be configured to monitor a temperature of water entering the water heater inlet and control the first valve dependent upon the monitored temperature.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.15/676,841, filed on Aug. 14, 2017, which is a continuation of U.S.application Ser. No. 14/746,403, filed on Jun. 22, 2015, now U.S. Pat.No. 9,732,536, which claims the benefit of U.S. Provisional ApplicationSer. No. 62/015,106, filed on Jun. 20, 2014, the disclosures of whichare incorporated by reference herein in their entirety.

BACKGROUND

Swimming pools and spas are popular with consumers in a wide variety ofenvironments. The type of pool or spa and the environment in which thepool or spa is operating in changes the user requirements formaintaining a pleasant experience. The temperature of the water in thepool or spa is one parameter that can be controlled that impacts theuser experience when swimming in a pool or relaxing in a spa.

Water heaters for all types of applications are well known in the art.With the wide variety of conditions, many different types of poolheaters have been developed that use different sources of energy to heatpool water. Different types of heaters that consume electricity or gashave certain advantages and disadvantages depending on the environmentalconditions. For example, traditional gas burning heaters may respondquickly to change the water temperature, but require a dedicated gassupply that may not be present in many warmer climate regions. Incontrast, electrically powered heat pumps can be configured to be veryefficient in warmer climates. However, the response time to heat thepool or spa water may be slower, and in cold conditions, the efficiencyis dramatically reduced. Many pool operators that are faced with avariety of environmental conditions have opted to install separateenergy source heaters to provide a heating unit that is appropriate fordifferent conditions. This solution is less than ideal. More space isrequired to install two or more heaters with each usually having aseparate controller. With separate controllers, the user or operatormust make the decision of which system to use and must manuallydetermine the most efficient operating schedule.

Therefore, there is a need in the art for a single, self-contained unitthat is adapted to be controlled by a single programmable controller tooperate multiple energy source heaters in a single housing to provideflexibility and cost effective heating.

SUMMARY

Some embodiments of the invention provide a water heater that includes aheat exchanger, a heat pump, a first valve in fluid communication withthe heat exchanger and the heat pump, and a controller configured tocontrol the first valve. The first valve can be configured to directwater flow toward at least one of the heat exchanger or the heat pump.

In some embodiments the first valve can be a three-way valve. In someembodiments the first valve can be a spring-loaded check valve.

Some embodiments can include a second valve in fluid communication withthe first valve and the heat pump, and in those embodiments thecontroller can be further configured to control the second valve.

In some embodiments the water heater can further include a housing, andthe heat exchanger and the heat pump can be mounted within the housing.

Some embodiments can include a water heater inlet and a water heateroutlet, whereby the first valve can be in fluid communication with thewater heater inlet and the water heater outlet. The controller can beconfigured to monitor a temperature of water entering the inlet of thewater heater and control the first valve dependent upon the temperatureof the water entering the inlet.

Some embodiments of the invention provide a water heater that includesan inlet, an outlet, a gas heater, an electric heat pump, and a waterflow control system with a first valve and a second valve connected inseries. The water flow control system can be configured to direct theflow of water from the inlet to at least one of the gas heater, theelectric heat pump, or the outlet.

In some embodiments the first valve can be a three-way valve. In someembodiments the first valve and the second valve can be spring-loadedcheck valves.

Some embodiments can further include a housing, wherein the gas heaterand the electric heat pump can be mounted within the housing.

In some embodiments the first valve can be in fluid communication withthe inlet, the second valve, and the gas heater. The second valve can bein fluid communication with the outlet, the first valve, and theelectric heat pump.

Some embodiments can include a controller configured to control the flowof water through water flow control system. The controller can beconfigured to monitor a temperature of water entering the inlet of thewater heater and can control the first valve and the second valvedependent upon the temperature of the water entering the inlet.

Some embodiments of the invention provide a water heater that includes agas heater, an electric heat pump, a first valve coupled to the gasheater, a second valve coupled to the electric heat pump, and acontroller configured to control the first valve and the second valve todirect water flow through at least one of the gas heater or the electricheat pump.

In some embodiments the controller can be configured to receive inputsignals relating to environmental conditions around the heater and anaquatic system in which the water heater is installed.

In some embodiments the controller can be programmed remotely by a user.

In some embodiments the controller can be configured to communicate withat least one component of an aquatic system in which the water heater isinstalled.

In some embodiments the controller can be configured to monitor atemperature of water entering an inlet of the water heater and cancontrol the first valve and the second valve dependent upon thetemperature of the water entering the inlet.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an aquatic system having a hybrid heateraccording to one embodiment of the invention;

FIG. 2 is an isometric view of an embodiment of a hybrid heater;

FIG. 3 is a different isometric view of the hybrid heater of FIG. 2;

FIG. 4 is another isometric view of the hybrid heater of FIG. 2 withportions removed therefrom for clarity;

FIG. 5 is an isometric view of some of the components of a heat pump ofthe hybrid heater of FIG. 2;

FIG. 6 is a different isometric view of the components of the heat pumpdepicted in FIG. 5;

FIG. 7 is an isometric view of a gas heater of the hybrid heater of FIG.2;

FIG. 8 is a different isometric view of the gas heater of FIG. 7;

FIG. 9 is another isometric view of some of the components of the hybridheater of FIG. 2;

FIG. 10 is a different isometric view of the components of the hybridheater of FIG. 9;

FIG. 11 is an isometric view of a further embodiment of a hybrid heaterwith portions removed therefrom for clarity;

FIG. 12 is an isometric view of a first side of another embodiment of ahybrid heater with portions removed therefrom for clarity;

FIG. 13 is an isometric view of a second side of the hybrid heater ofFIG. 12 with portions removed therefrom for clarity;

FIG. 14 is an isometric view of a first side of yet another embodimentof a hybrid heater with portions removed therefrom for clarity;

FIG. 15 is an isometric view of a second side of the hybrid heater ofFIG. 14 with portions removed therefrom for clarity;

FIG. 16 is a flow chart of a first mode of operation of any of thehybrid heaters disclosed herein;

FIG. 17 is a flow chart of a second mode of operation of any of thehybrid heaters disclosed herein;

FIG. 18 is a flow chart of a third mode of operation of any of thehybrid heaters disclosed herein; and

FIG. 19 is a flow chart of a fourth mode of operation of any of thehybrid heaters disclosed herein.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

The following discussion is presented to enable a person skilled in theart to make and use embodiments of the invention. Various modificationsto the illustrated embodiments will be readily apparent to those skilledin the art, and the generic principles herein can be applied to otherembodiments and applications without departing from embodiments of theinvention. Thus, embodiments of the invention are not intended to belimited to embodiments shown, but are to be accorded the widest scopeconsistent with the principles and features disclosed herein. Thefollowing detailed description is to be read with reference to thefigures, in which like elements in different figures have like referencenumerals. The figures, which are not necessarily to scale, depictselected embodiments and are not intended to limit the scope ofembodiments of the invention. Skilled artisans will recognize theexamples provided herein have many useful alternatives and fall withinthe scope of embodiments of the invention.

The embodiments described below pertain to a tankless hybrid waterheater. Specifically, the tankless heater includes a first gas burningheater and a second electrically powered heat pump that may be used toheat water for a pool, spa, or other aquatic application. The tanklesshybrid water heater employs a single housing with two different types ofheaters and includes a programmable controller.

The embodiments of the present disclosure include numerous advantagesover the prior art. For example, one advantage is two different types ofheaters being provided in a single housing. By providing two differenttypes of heaters in one device, the space required for installation maybe significantly reduced when compared to installing two separateheaters. Another advantage is use of a single programmable controllerthat can utilize the different heaters in a variety of operationalmodes. Thus, the embodiments of the present disclosure are capable ofproviding significantly improved performance with respect to energyconsumption and response time as desired by the operator of the tanklesshybrid water heater.

Referring to FIG. 1, a schematic diagram of an aquatic system 100 isdepicted. A pool, spa, or other aquatic application 102 is connected toa pump 104 (P1), which is in fluid communication with a filter 106 (F1)and a tankless hybrid heater 108. The aquatic application 102, the pump104, the filter 106, and the hybrid heater 108 are connected by a seriesof pipes represented by arrows in FIG. 1. It is contemplated that onehaving ordinary skill in the art would understand that the embodiment ofthe aquatic system 100, and all of the components described therein,provided in the present disclosure may be configured in many differentways not specifically disclosed herein.

Still referring to FIG. 1, the hybrid heater 108 includes a housing 110,which further includes an inlet 112 and an outlet 114. The inlet 112 isin fluid communication with the filter 106 and the outlet 114 is influid communication with the aquatic application 102. The hybrid heater108 also includes a first valve 116 (V1) that is in fluid communicationwith the inlet 112. The first valve 116 is also in fluid communicationwith a tankless gas heater 118 (TGH) and/or a second valve 120 (V2). Thesecond valve 120 is further in fluid communication with a tanklesselectric heat pump 122 (THP) and/or a by-pass pipe 124. The tankless gasheater 118 includes a gas heater inlet pipe 126 and a gas heater outletpipe 128. The gas heater inlet pipe 126 is in fluid communication withthe first valve 116. The gas heater outlet pipe 128 is in fluidcommunication with the outlet 114. The first valve 116 is in fluidcommunication with the second valve 120 through a transfer pipe 130. Thetankless heat pump 122 includes a heat pump inlet pipe 132, which is influid communication with the second valve 120, and a heat pump outletpipe 134, which is in fluid communication with the outlet 114.

As can be seen in FIG. 1, the hybrid heater 108 includes a single inlet112 and a single outlet 114 that transport water to both the tanklessgas heater 118 and the tankless heat pump 122. The first and secondvalves 116, 120 control the flow of water into one or both of thetankless gas heater 118 and the tankless heat pump 122 through the pipes130, 132 and/or the by-pass pipe 124.

The hybrid heater 108 also includes a controller 136 that may beprogrammable and may be in communication with one or more of the firstvalve 116, the gas heater 118, the second valve 120, and the heat pump122 (shown via dashed arrows in FIG. 1). The controller 136 may also beconfigured to communicate with all or some of the components of theaquatic system 100 external to the hybrid heater 108, such as the filter106 and/or the pump 104. In an alternative embodiment, the hybrid heater108 and the controller 136 may be configured to be in communication withand controlled by an external controller (not shown) that may be incommunication with and controlling some or all of the other componentsof the aquatic system 100. Furthermore, the controller 136 may beconfigured to receive many different types of input signals in relatingto environmental conditions around the hybrid heater 108 and the aquaticapplication 102 by any variety of sensors and gauges known to thosehaving ordinary skill in the art. It is also contemplated that, inanother alternative embodiment, the controller 136 may includecommunication capability to send and receive information via wirelesstechnologies to different components of the aquatic system 100 orinterface with a remote user. In a further alternative embodiment, theprogramming of the controller 136 may be performed remotely or locallyby the user through a user interface (not shown).

Turning now to FIGS. 2 and 3, one embodiment of a tankless hybrid heater208 is depicted. The hybrid heater 208 includes a housing 210, whichfurther includes an inlet 212 and an outlet 214. A first valve 216 is influid communication with the inlet 212 and a tankless gas heater 218,and/or a second valve 220 (see FIG. 5). The second valve 220 is in fluidcommunication with a tankless heat pump 222 (see FIGS. 5 and 6), and/ora bypass pipe 224 (see FIG. 6). The tankless gas heater 218 includes agas heater inlet pipe 226, which is in fluid communication with thefirst valve 216, and a gas heater outlet pipe 228, which is in fluidcommunication with the outlet 214. The first valve 216 is in fluidcommunication with the second valve 220 through a transfer pipe 230. Thetankless heat pump 222 includes a heat pump inlet pipe 232 (see FIG. 5),which is in fluid communication with second valve 220, and a heat pumpoutlet pipe 234 (see FIG. 6), which is in fluid communication with theoutlet 214. The hybrid heater 208 also includes a controller 236 thatmay be programmable and may be in communication with one or more of thefirst valve 216, the tankless gas heater 218, the second valve 220,and/or the tankless heat pump 222.

While the second valve 220 is described as being a valve, the secondvalve 220 may be any component that directs flow to the bypass pipe 224,the heat pump inlet pipe 232, or both the bypass pipe 224 and the heatpump inlet pipe 232 simultaneously. In one embodiment, the second valve220 may be a T-elbow. In another embodiment, the second valve 220 may bea solenoid valve.

Still referring to FIGS. 2 and 3, the housing 210 includes an upperhousing portion 240 and a lower housing portion 242. The upper housingportion 240 is connected to the lower housing portion 242 by twovertical supports 244 (see FIG. 4). The upper housing portion 240defines an opening 246 to allow airflow through the housing 210. A fanguard 248 is disposed on the upper housing portion 240 across theopening 246. A fan 250 (see FIG. 4) of the heat pump 222 is supported inthe opening 246 by the fan guard 248. The gas heater 218 is supported onthe housing 210 by horizontal supports 252. A mesh screen 254 covers arefrigerant-to-air heat exchanger 256 (see FIG. 4) and extends from theupper housing portion 240 to the lower housing portion 242. It iscontemplated that in some embodiments, the gas heater 218 and the heatpump 222 may both be contained within the housing 210. Further, in someembodiments, the housing may take different configurations to includethe gas heater 218 and heat pump 222 in different configurations asunderstood by one having ordinary skill in the art.

Referring now to FIG. 4, the hybrid heater 208 depicted has the upperhousing portion 240, fan guard 248, and mesh screen 254 removed toreveal the refrigerant-to-air heat exchanger 256 and the fan 250 of theheat pump 222.

FIGS. 5 and 6 depict various components of the heat pump 222 of thehybrid heater 208 with the refrigerant-to-air heat exchanger 256 and fan250 removed for clarity. The heat pump 222 includes a compressor 260, arefrigerant-to-water heat exchanger 262, the fan 250, therefrigerant-to-air heat exchanger 256, and the associated lines(unlabeled) to allow refrigerant to flow between components of the heatpump 222 during operation.

Now turning to FIGS. 7 and 8, one embodiment of the gas heater 218 ofhybrid heater 208 is depicted. The gas heater 218 includes a heaterhousing 264 and a blower 266, which includes an electric blower motor268 and an blower air inlet 270. The heater housing 264 includes anexhaust port 272, a water inlet port 274, and a water outlet port 276.Contained within the heater housing is a gas burning tankless water heatexchanger (not shown).

In the embodiment depicted in FIGS. 2-4, the controller 236 controls theoperation of the heat pump 222. Water enters the heat pump 222 afterpassing through the second valve 220 and flowing into the heat pumpinlet pipe 232. The water then flows into the refrigerant-to-water heatexchanger 262 where the heat from vaporized compressed refrigerant istransferred to the water and the refrigerant condenses to a liquid. Theheated water then exits the heat pump 222 through the heat pump outletpipe 234 and enters the outlet 214. The condensed refrigerant flows intothe refrigerant-to-air heat exchanger 256 to absorb heat from air pushedthrough the housing 210 by the fan 250. Absorbing heat vaporizes theliquid refrigerant before flowing into the compressor 260. The vaporizedrefrigerant is then compressed by the compressor 260 to increase thetemperature and pressure of the vaporized refrigerant before beingpumped back into the refrigerant-to-water heat exchanger 262 to repeatthe process. It is further contemplated that different types ofrefrigerant and different types of heat pumps known to one havingordinary skill in the art may be used in place of the embodimentdescribed above.

Still referring to the embodiment depicted in FIGS. 2-4, the controller236 controls the operation of the gas heater 218. Water flows from thefirst valve 216 through the gas heater inlet pipe 226 and into the gasheater water inlet port 274. The water flows from the water inlet port274 into the gas burning heat exchanger (not shown). During theoperation of the heater 218, the blower motor 268 turns a fan blade (notshown) within the blower 266 pulling in fresh air through the blower airinlet 270. The fresh air is mixed with gas within the heater housing 264and the gas/air mixture is combusted to provide heat. The heated waterthen exits the heater housing 264 through the water outlet port 276 intothe gas heater outlet pipe 228 to flow into the outlet 214. Exhaust gasfrom the heater exits through the exhaust port 272 into an exhaust pipe(not shown) that carries the exhaust gas a safe distance away from thehybrid heater 208 depending on the type of installation. It iscontemplated that other styles and types of tankless gas heaters knownto one having ordinary skill in the art may be substituted for theembodiment described above.

Referring now to FIGS. 9 and 10, the components of the hybrid heater 208that may contain flowing water are depicted. The operator and/or thecontroller 236 may determine the water flow path during operation of thehybrid heater 208. The first valve 216 may be configured to direct theflow of water in three different ways. In a first configuration, thefirst valve 216 may direct water only to the gas heater 218 through thegas heater inlet pipe 226. Water then flows from the gas heater 218through the gas heater outlet pipe 228 into the outlet 214 to return tothe aquatic application 102. In a second configuration, the first valve216 may direct water only to the second valve 220 through the transferpipe 230 and prevent water from flowing to the gas heater 218. In athird configuration, the first valve 216 may direct water to flow toboth the gas heater 218 and the second valve 220 simultaneously.

The second valve 220 may be configured to direct the flow of water intwo different ways. In a first configuration, the second valve 220 maydirect the flow of water only to the heat pump 222 through the heat pumpinlet pipe 232. Water then flows out from the heat pump 222 through theheat pump outlet pipe 234 into the outlet 214 to return to the aquaticapplication 102. In a second configuration, the second valve 220 maydirect water only to the bypass pipe 224. Water flowing through thebypass pipe may only enter the outlet 214 to return to the aquaticapplication 102. It is contemplated that in some embodiments, the firstvalve 216 and the second valve 220 are in communication with andcontrolled by the controller 236 automatically. Alternatively, in someembodiments, the first valve 216 and the second valve 220 may beactuated manually by the user and/or may be actuated automatically bythe controller 236. The different configurations of the first valve 216and the second valve 220 are independent of one other and allow formultiple modes of operation of the hybrid heater 208.

Referring now to FIG. 11, a further embodiment of a hybrid heater 208 isdepicted. The hybrid heater 208 includes the same or similar componentsas the hybrid heater of FIGS. 1-10 in a different arrangement within thehousing 210 and, thus, the same reference numerals will be utilized.Similar to the embodiment of FIGS. 1-10, the hybrid heater 208 includesa housing 210, which includes an inlet 212 and an outlet 214. A firstvalve 216 is in fluid communication with the inlet 212 and a tanklessgas heater 218, and/or a second valve 220. The second valve 220 is influid communication with a tankless heat pump 222, and/or a bypass pipe224. The tankless gas heater 218 includes a gas heater inlet pipe 226,which is in fluid communication with the first valve 216, and a gasheater outlet pipe 228, which is in fluid communication with the outlet214. The first valve 216 is in fluid communication with the second valve220 through a transfer pipe 230. The tankless heat pump 222 includes aheat pump inlet pipe 232, which is in fluid communication with secondvalve 220, and a heat pump outlet pipe 234, which is in fluidcommunication with the outlet 214. The hybrid heater 208 also includes acontroller (not shown) that may be programmable and may be incommunication with one or more of the first valve 216, the tankless gasheater 218, the second valve 220, and/or the tankless heat pump 222.

The hybrid heater 208 may operate in the same fashion and/or include anyof the same components as the hybrid heater disclosed in relation toFIGS. 1-10. One of the main differences between the two embodiments isthe location and orientation of the inlet and outlet 212, 214 andvarious pipes 226, 228, 230, 232, 234. In addition, in order to reducean overall size of the housing 210, the compressor 260 of heat pump isdisposed within the heat exchanger 262.

A further embodiment of a hybrid heater 208 is depicted in FIGS. 12 and13. As with the embodiment of FIG. 11, the hybrid heater 208 includesthe same or similar components as the hybrid heater of FIGS. 1-10 in adifferent arrangement within the housing 210 and, thus, the samereference numerals will be utilized. Similar to the embodiments of FIGS.1-10 and 11, the hybrid heater 208 includes a housing 210, whichincludes an inlet 212 and an outlet 214. A first valve 216 is in fluidcommunication with the inlet 212 and a tankless gas heater 218, and/or asecond valve 220. The second valve 220 is in fluid communication with atankless heat pump 222, and/or a bypass pipe 224. The tankless gasheater 218 includes a gas heater inlet pipe 226, which is in fluidcommunication with the first valve 216, and a gas heater outlet pipe228, which is in fluid communication with the outlet 214. The firstvalve 216 is in fluid communication with the second valve 220 through atransfer pipe 230. The tankless heat pump 222 includes a heat pump inletpipe 232, which is in fluid communication with second valve 220, and aheat pump outlet pipe 234, which is in fluid communication with theoutlet 214. The hybrid heater 208 also includes a controller (not shown)that may be programmable and may be in communication with one or more ofthe first valve 216, the tankless gas heater 218, the second valve 220,and/or the tankless heat pump 222.

The hybrid heater 208 may operate in the same fashion and/or include anyof the same components as the hybrid heaters disclosed in relation toFIGS. 1-10 and 11. One of the main differences between the presentembodiments and the other embodiments disclosed herein is the locationand orientation of the inlet and outlet 212, 214 and various pipes 226,228, 230, 232, 234. In addition, similar to the embodiment of FIG. 11,in order to reduce an overall size of the housing 210, the compressor260 of heat pump is disposed within the heat exchanger 262.

Another embodiment of a hybrid heater 208 is depicted in FIGS. 14 and15. Similar to the previous embodiments, the hybrid heater 208 includesthe same or similar components as the hybrid heater of FIGS. 1-10 in adifferent arrangement within the housing 210 and, thus, the samereference numerals will be utilized. Similar to the previousembodiments, the hybrid heater 208 includes a housing 210, whichincludes an inlet 212 and an outlet 214. A first valve 216 is in fluidcommunication with the inlet 212 and a tankless gas heater 218, and/or asecond valve 220. The second valve 220 is in fluid communication with atankless heat pump 222 and the valves 216 and 220 control flow ofthrough a bypass pipe 224. The tankless gas heater 218 includes a gasheater inlet pipe 226, which is in fluid communication with the firstvalve 216, and a gas heater outlet pipe 228, which is in fluidcommunication with the outlet 214. The first valve 216 is in fluidcommunication with the second valve 220 through a transfer pipe 230. Thetankless heat pump 222 includes a heat pump inlet pipe 232, which is influid communication with second valve 220, and a heat pump outlet pipe234, which is in fluid communication with the outlet 214. The hybridheater 208 also includes a controller (not shown) that may beprogrammable and may be in communication with one or more of the firstvalve 216, the tankless gas heater 218, the second valve 220, and/or thetankless heat pump 222.

The hybrid heater 208 may operate in the same fashion and/or include anyof the same components as the hybrid heaters disclosed in relation toFIGS. 1-10, 11, and 12-13. One of the main differences between thepresent embodiments and the other embodiments disclosed herein is thelocation and orientation of the inlet and outlet 212, 214 and variouspipes 226, 228, 230, 232, 234. In addition, similar to the embodimentsof FIGS. 11 and 12-13, in order to reduce an overall size of the housing210, the compressor 260 of heat pump is disposed within the heatexchanger 262.

It is contemplated that different types of valves than the typesdisclosed may be employed in any of the embodiments disclosed. Forexample, spring loaded check valves may be used in place of the firstvalve 216 and/or the second valve 220. One advantage of using acombination of check valves may be to provide a minimum flow at alltimes through the gas heater 218 and/or the heat pump 222. It is alsocontemplated that multiple types of valves may be used in differentcombinations to provide different configurations of water flow dependenton the capabilities of the system.

Any of the hybrid heaters 208 disclosed herein may enable differentmodes of operation that benefit the user/operator. The controller 236may monitor at least the temperature of the water in the inlet 212 byvarious sensors, gauges, and the like. A set point temperature 280 maybe stored within the memory of the controller 236. During operation ofthe hybrid heater 208, the controller 236 may compare the set pointtemperature 280 to at least the temperature of the water in the inlet212. It is contemplated that during operation of the hybrid heater 208,the controller 236 may include programming to allow thermostat-likefunctioning during the different modes of operation as understood by onehaving ordinary skill in the art to prevent unnecessary activationand/or deactivation of the hybrid heater 208. In some embodiments, aphysical thermostat (not shown) may be in signal communication with thecontroller 236. In other embodiments, the controller programming mayinclude one or more timers, delays, or other techniques or technologiesto prevent undesirable cycling of the hybrid heater 208.

A first mode of operation or gas heater only mode 290, uses only the gasheater 218 to heat water. A second mode of operation or heat pump onlymode 292, uses only the heat pump 222 to heat water. A third mode ofoperation or boost mode 294 includes using both the gas heater 218 andthe heat pump 222 simultaneously. In boost mode 294, water flows throughboth the heat pump 222 and the gas heater 218 in a parallel-likeconfiguration. A fourth mode of operation or hybrid mode 296 includesusing the heat pump 222 as a primary heater and the gas heater 218 as asecondary heater. The controller 236 may configure the first valve 216and the second valve 220 to flow water through the heat pump 222 forprimary heating and flow water through the gas heater 218 as needed. Afifth mode of operation or bypass mode includes the first valve 216 andthe second valve 220 configured to only flow water through the bypasspipe 224 when heating the water is not necessary. In any of the modes ofoperation, the controller 236 may activate the gas heater 218 and/orheat pump 222 accordingly and/or may configure the first valve 216and/or second valve 220 accordingly. All the modes of operation will bediscussed in detail below.

During the first mode of operation or gas heater only mode 290, thecontroller 236 (see FIGS. 2-4) or user may activate the gas heater 218.A flow chart depicting the gas heater only mode 290 is depicted in FIG.16. After the start block 320 of the gas heater only mode 290, with thefirst block 322, the controller 236 compares the temperature (T) of thewater in the inlet 212 to the set point temperature 280 (Tset). If thetemperature (T) is below the set point temperature 280 (Tset), the gasheater 218 is activated by the controller 236 in block 324. Thedifference between the inlet 212 temperature (T) and the set pointtemperature 280 (Tset) sufficient to trigger the controller 236 toactivate the gas heater 218 may be configured by the user or it may be adefault setting in the controller 236 programming. While the gas heater218 is operating, the controller 236 will monitor the inlet 212temperature (T) and compare it with the set point temperature 280 (Tset)in block 326. If the temperature (T) of the inlet 212 is below the setpoint temperature 280 (Tset), the controller 236 continues to monitorthe temperature (T) of the inlet 212 while the gas heater 218 operates.If the temperature (T) of the inlet 212 is equal to or above the setpoint temperature 280 (Tset), the controller 236 proceeds to block 328and deactivates the gas heater 218. The controller 236 will then waitfor a specific period of time or proceed back to block 322 until theinlet 212 temperature (T) drops below the set point temperature 280(Tset) as described above or the gas heater only mode 290 is ended withblock 330.

Still referring to FIG. 16, after the start block 320, the inlet 212temperature (T) may be at or above the set point temperature 280 (Tset).The controller 236 would then proceed directly to block 328. It iscontemplated that in some embodiments, water is continuously flowingthrough the gas heater 218 while the hybrid heater 208 is in the gasheater only mode 290. In an alternative embodiment, when the controller236 reaches block 328, the controller 236 may configure the first valve216 and the second valve 220 to direct the water to flow through thebypass pipe 224 during periods when the gas heater 218 is deactivated.It is also contemplated that the start 320 and end 330 of the gas heater218 only mode 290 may be triggered by the user or the controller 236 invarious circumstances.

During the second mode of operation or heat pump only mode 292, thecontroller 236 or user may activate only the heat pump 222. A flow chartdepicting the heat pump only mode 292 is depicted in FIG. 17. After thestart block 332 of the heat pump only mode 292, with the first block334, the controller 236 compares the temperature (T) of the water in theinlet 212 to the set point temperature 280 (Tset). If the temperature(T) is below the set point temperature 280 (Tset), the heat pump 222 isactivated by the controller 236 in block 336. The difference between theinlet 212 temperature (T) and the set point temperature 280 (Tset)sufficient to trigger the controller 236 to activate the heat pump 222may be configured by the user or it may be a default setting in thecontroller 236 programming. While the heat pump 222 is operating, thecontroller 236 will monitor the inlet 212 temperature (T) and compare itwith the set point temperature 280 (Tset) in block 338. If thetemperature (T) of the inlet 212 is below the set point temperature 280(Tset), the controller 236 continues to monitor the temperature (T) ofthe inlet 212 while the heat pump 222 operates. If the temperature (T)of the inlet 212 is equal to or above the set point temperature 280(Tset), the controller 236 proceeds to block 340 and deactivates theheat pump 222. The controller 236 will then wait for a specific periodof time or proceed back to block 334 until the inlet 212 temperature (T)drops below the set point temperature 280 (Tset) as described above orthe heat pump only mode 292 is ended with block 342.

Still referring to FIG. 17, after the start block 332, the inlet 212temperature (T) may be at or above the set point temperature 280 (Tset).The controller 236 would then proceed directly to block 340. It iscontemplated that in some embodiments, water is continuously flowingthrough the heat pump 222 while the hybrid heater 208 is in the heatpump only mode 292. In an alternative embodiment, when the controller236 reaches block 340, the controller 236 may configure the first valve216 and the second valve 220 to direct the water to flow through thebypass pipe 224 during periods when the heat pump 222 is deactivated. Itis also contemplated that the start 332 and end 342 of the heat pumponly mode 292 may be triggered by the user or the controller 236 invarious circumstances.

During the third mode of operation or boost mode 294, the controller 236or user may activate the gas heater 218 and the heat pump 222 at thesame time. A flow chart depicting the boost mode 294 is depicted in FIG.18. After the start block 344 of the gas heater only mode 290, at thefirst block 346, the controller 236 compares the temperature (T) of thewater in the inlet 212 to the set point temperature 280 (Tset). If thetemperature (T) is below the set point temperature 280 (Tset), the gasheater 218 and the heat pump 222 are activated by the controller 236 inblock 348. The difference between the inlet 212 temperature (T) and theset point temperature 280 (Tset) sufficient to trigger the controller236 to activate the gas heater 218 and the heat pump 222 may beconfigured by the user or it may be a default setting in the controller236 programming. While the gas heater 218 and the heat pump 222 areoperating, the controller 236 will monitor the inlet 212 temperature (T)and compare it with the set point temperature 280 (Tset) in block 350.If the temperature (T) of the inlet 212 is below the set pointtemperature 280 (Tset), the controller 236 continues to monitor thetemperature (T) of the inlet 212 while the gas heater 218 and the heatpump 222 operate. If the temperature (T) of the inlet 212 is equal to orabove the set point temperature 280 (Tset), the controller 236 proceedsto block 352 and deactivates the gas heater 218 and the heat pump 222.The controller 236 will then wait for a specific period of time orproceed back to block 346 until the inlet 212 temperature (T) dropsbelow the set point temperature 280 (Tset) as described above or theboost mode 294 is ended with block 354.

Still referring to FIG. 18, after the start block 344, the inlet 212temperature (T) may be at or above the set point temperature 280 (Tset).The controller 236 would then proceed directly to block 352. It iscontemplated that in some embodiments, water is continuously flowingthrough the gas heater 218 and the heat pump 222 while the hybrid heater208 is in the boost mode 294. In an alternative embodiment, when thecontroller 236 reaches block 352, the controller 236 may configure thefirst valve 216 and the second valve 220 to direct the water to flowthrough the bypass pipe 224 during periods when the gas heater 218 andthe heat pump 222 are deactivated. It is also contemplated that thestart 344 and end 354 of the boost mode 294 may be triggered by the useror the controller 236 in various circumstances. It is furthercontemplated that boost mode 294 would provide the maximum heat outputof the hybrid heater 208 and thus reach the set point temperature 280(Tset) the fastest of all the operational modes.

FIG. 19 depicts a flow chart for a fourth mode of operation or hybridmode 296. After the start block 356 of hybrid mode 296, with the firstblock 358, the controller 236 compares the temperature (T) of the waterin the inlet 212 to the set point temperature 280 (Tset). If thetemperature (T) is 10 degrees or more below the set point temperature280 (Tset), the gas heater 218 and the heat pump 222 are activated bythe controller 236 in block 360. While the gas heater 218 and the heatpump 222 are operating, the controller 236 will monitor the inlet 212temperature (T) and compare it with the set point temperature 280 (Tset)in block 362. If the temperature (T) of the inlet 212 is below the setpoint temperature 280 (Tset), the controller 236 continues to monitorthe temperature (T) of the inlet 212 while the gas heater 218 and theheat pump 222 operate. If the temperature (T) of the inlet 212 is equalto or above the set point temperature 280 (Tset), the controller 236proceeds to block 364 and deactivates the gas heater 218 and the heatpump 222. If the inlet 212 temperature (T) is not 10 degrees or morebelow the set point temperature 280 (Tset), the controller proceeds toblock 366. The controller 236 then compares the inlet 212 temperature(T) to the set point temperature 280 (Tset). If the temperature (T) isbelow the set point temperature 280 (Tset), the heat pump 222 isactivated by the controller 236 in block 368. During hybrid mode 296,when the heat pump 222 is activated in block 368, the controller 236monitors the temperature (T) in block 370 differently than in the othermodes of operation. If the temperature (T) is more than a value Xdegrees below the set point temperature 280 (Tset), the controllerproceeds to block 372, where the time the heat pump 222 has beenactivated is compared to a value Y. If the heat pump 222 has beenoperating for a time period equal to or more than the value Y, thecontroller 236 proceeds to block 360 and turns on the gas heater 218also. The controller 236 then proceeds as described above. If at block372, the time the heat pump 222 has been operating is less than thevalue Y, the controller proceeds to block 374, where if the temperature(T) of the inlet 212 is below the set point temperature 280 (Tset), thecontroller 236 proceeds back to block 370. When the temperature (T) isequal to or above the set point temperature (Tset) in block 374, thecontroller 236 proceeds to block 364 and deactivates the heat pump 222.The controller 236 will then wait for a specific period of time orproceed back to block 358. Hybrid mode 296 may continue until the useror controller 236 ends the mode and the controller proceeds to the endblock 376.

Still referring to FIG. 19, after the start block 356, the inlet 212temperature (T) may be at or above the set point temperature 280 (Tset).The controller 236 would then proceed to block 364. It is contemplatedthat in some embodiments, water only flows through the heat pump 222 andthe gas heater 218 when the respective units are activated. When thecontroller 236 reaches block 364, the controller 236 may configure thefirst valve 216 and the second valve 220 to direct the water to flowthrough the bypass pipe 224 during periods when the gas heater 218 andthe heat pump 222 are deactivated.

In some embodiments, the value X and the value Y may be programmed orselected by a user. Alternatively, the value X and the value Y may bepre-programmed into the controller 236. In further embodiments, thevalue X and the value Y may be adjusted by the controller 236 from theprogrammed or selected values depending on environmental and/or otherconditions. One advantage of hybrid mode 296 is that the hybrid heater208 will maintain the water temperature of the aquatic application 102even if the environmental conditions results in less than optimaloperating conditions for the heat pump 222, while still attempting tomaximize the efficiency of the electricity consumed by the heat pump 222and minimize the gas consumed by the gas heater 218.

During a fifth mode of operation or bypass mode, the controller 236 oroperator configures the first valve 216 and the second valve 220 so thatwater only flows through the bypass pipe 224. During this mode ofoperation the heat pump 222 and the gas heater 218 are deactivated andno water is flowing through either. In one embodiment, bypass mode 298may be a subroutine of the other modes of operation of the hybrid heater208. Once the set point temperature 280 (Tset) is achieved in any of theother modes, the controller 236 may enter the hybrid heater 208 intobypass mode 298. The hybrid heater 208 may remain in bypass mode 298until the controller 236 determines the inlet 212 temperature (T) is nolonger at or above the set point temperature 280 (Tset). The controller236 may then enter the hybrid heater 208 into the previously selectedmode of operation or another mode of operation depending onenvironmental conditions or other factors. Alternatively, during thefifth mode of operation or bypass mode, the controller 236 maydeactivate both the gas heater 218 and the heat pump 222 and the valves216, 220 would provide at least a minimum flow of water to the gasheater 218 and heat pump 222, respectively.

As noted above, the valves 216, 220 regulate an amount of water that istransferred to each of the gas heater 218 and the heat pump 222,respectively. In some embodiments, when the gas heater 218 and/or theheat pump 222 are deactivated, the valves 216, 220, respectively, mayprovide a minimum flow to the gas heater 218 and/or the heat pump 222.In a scenario when less than a full flow is necessary to the heat pump222, the valve 220 additionally directs any excess water flow throughthe bypass pipe 224 toward the outlet 214.

It is further contemplated that the mode of operation may be chosen bythe user or the controller 236. The controller 236 may be configured toreceive input signals from a variety of sensors and sources. The inputsignals may characterize all of the relevant information and datarelative to the aquatic system 100. The controller 236 may be configuredto also receive information relative to gas and electric utility costseither manually entered by a user or via an internet connection. Thecontroller 236 may also be configured to receive weather and temperatureinformation from sensors in communication with the controller 236 or viaan internet connection. It is further contemplated that the controller236 may be configured to process some or all of the data received tochoose the most appropriate mode of operation of the hybrid heater 208.The mode of operation may be selected by the controller 236 dependent onfactors chosen by the user such as, for example, minimizing operationalcost or maintaining a tight tolerance on the set point temperature 280.

It will be appreciated by those skilled in the art that while theinvention has been described above in connection with particularembodiments and examples, the invention is not necessarily so limited,and that numerous other embodiments, examples, uses, modifications anddepartures from the embodiments, examples and uses are intended to beencompassed by the claims attached hereto. The entire disclosure of eachpatent and publication cited herein is incorporated by reference, as ifeach such patent or publication were individually incorporated byreference herein. Various features and advantages of the invention areset forth in the following claims.

The invention claimed is:
 1. A water heater comprising: a heatexchanger; a heat pump; a first valve in fluid communication with theheat exchanger and the heat pump, the first valve configured to directwater flow in a first configuration toward one of the heat exchanger orthe heat pump, and in a second configuration toward both the heatexchanger and the heat pump; and a controller configured to control thefirst valve.
 2. The water heater of claim 1, wherein the first valve isa three-way valve.
 3. The water heater of claim 1, wherein the firstvalve is a spring-loaded check valve.
 4. The water heater of claim 1 andfurther comprising a second valve in fluid communication with the firstvalve and the heat pump, and wherein the controller is furtherconfigured to control the second valve.
 5. The water heater of claim 1and further comprising a housing; and wherein the heat exchanger and theheat pump are mounted within the housing.
 6. The water heater of claim 1and further comprising a water heater inlet and a water heater outlet;and wherein the first valve is in fluid communication with the waterheater inlet and the water heater outlet.
 7. The water heater of claim6, wherein the controller is configured to monitor a temperature ofwater entering the water heater inlet and controls the first valvedependent upon the temperature of water entering the water heater inlet.8. A water heater comprising: an inlet; an outlet; a gas heater; anelectric heat pump; and a water flow control system with a first valveand a second valve connected in series, the water flow control systemconfigured to direct water flow from the inlet to: only the gas heater;only the electric heat pump; both the gas heater and the electric heatpump; and only to the outlet.
 9. The water heater of claim 8, whereinthe first valve is a three-way valve.
 10. The water heater of claim 8,wherein the first valve and the second valve are spring-loaded checkvalves.
 11. The water heater of claim 8 and further comprising ahousing; and wherein the gas heater and the electric heat pump aremounted within the housing.
 12. The water heater of claim 8, wherein thefirst valve is in fluid communication with the inlet, the second valve,and the gas heater.
 13. The water heater of claim 8, wherein the secondvalve is in fluid communication with the outlet, the first valve, andthe electric heat pump.
 14. The water heater of claim 8 and furthercomprising a controller configured to control the water flow through thewater flow control system.
 15. The water heater of claim 14, wherein thecontroller is configured to monitor a temperature of water entering theinlet of the water heater and controls the first valve and the secondvalve dependent upon the temperature of water entering the inlet.
 16. Awater heater comprising: a gas heater; an electric heat pump; a firstvalve coupled to the gas heater; a second valve coupled to the electricheat pump; and a controller configured to control the first valve andthe second valve to direct water flow through one and both of the gasheater and the electric heat pump.
 17. The water heater of claim 16,wherein the controller is configured to receive input signals relatingto environmental conditions around the water heater and an aquaticsystem in which the water heater is installed.
 18. The water heater ofclaim 16, wherein the controller is configured to be programmed remotelyby a user.
 19. The water heater of claim 16, wherein the controller isconfigured to communicate with at least one component of an aquaticsystem in which the water heater is installed.
 20. The water heater ofclaim 16, wherein the controller is configured to monitor a temperatureof water entering an inlet of the water heater and controls the firstvalve and the second valve dependent upon the temperature of waterentering the inlet.